Optimization of the handling behaviour of an electric car by adjusting the kinematic gains of suspension

Abstract In this paper, within the scope of development of an electric car on a vehicle platform that is borned as internal combustion engine is presented. The vehicle dynamics behaviour changes due to the change of weight distribution and centre of gravity. Replacing the internal combustion engine with an electric motor, plus the addition of the battery moves the center of gravity towards the rear of the vehicle. Due to the increase in the rear axle load, the tendency of the vehicle to oversteer increases. To overcome this phenomenon, the rear suspension kinematic gains (camber, toe change due to vertical movement of the wheel) are adjusted thanks to the multi-link suspension. In the fist part of the study the platform is measured and Admas Car model is correlated depends on measured handling metrics. Subsequently, centre of gravity changes are applied to the verified Adams Car model. Also main platform handling metrics is defined as design targets and rear axle kinematic gains are defined as design parameters. A design of experiments (DOE)-based optimization study was performed via Adams®/Insight commercial software to achieve required handling metrics which satisfy design targets. Kinematic gains of the suspension system is analyzed via Adams car and sensitivity deepens on harpoints is determined. Design space for hardpoints is determined depends on mechanical design. The lowest and highest points are determined on the x, y and z axis and experiment list are designed according to DOE. Maneuvers that are for measuring the handling metrics are performed one after the other by changing the parameters according to the boundary conditions comes from DOE. A regression mathematical model is obtained and optimum parameters are calculated for the handling behaviour optimisation. Optimum parameters are applied on the Adams Car model again and handling manoeuvres are repeated. Results show that, although weight distribution changes, handling behaviours remain the same as based platform.